����ý

For two well-known custom processors, it was all about collaboration. And, in the end, and got together to develop material and processing technology that enabled the end user to bring to market a thermoformed EV charging station, also known as a DC Block.

The OEM had previously used various other manufacturing processes such as injection molding, structural foam, reaction injection molding (RIM) and sheet metal for its equipment covers. However, the products developed from these processes either failed to meet the stringent outdoor requirements or required secondary finishing operations. Specifically, the RIM process fell short of meeting outdoor UL requirements, while sheet metal and structural foam required additional painting, which introduced higher costs and susceptibility to scratching.

Featured Content

Automatic Conveying with AI Optimization READ MORE

A Purge Solution for the Blow Molding and Compounding Industries READ MORE

A Simpler Way to Calculate Shot Size vs. Barrel Capacity READ MORE

Considering the charging unit contained 11 parts with an average part size of 3 × 3 ft., the customer desired a solution that provided lower tooling costs than injection molding. The project also required material that would not only meet the UL746C F1 and V-0 standards but also match the aesthetics of aluminum and withstand UV exposure and severe weather conditions. In addition, the goal was to simplify assembly by minimizing attachment points, which required molded-in features to eliminate the need for secondary bonding of blocks or bosses.

When Ray Products was approached with the DC Block project, the team leveraged its extensive experience in thermoforming and long-standing partnership with sheet processor Sekisui Kydex. The challenge required a thermoplastic material that could withstand outdoor conditions, meet stringent UL standards and offer a high-quality, in-mold color finish to eliminate the need for secondary painting. Drawing from its history of identifying and executing the most effective solutions, Ray Products saw an opportunity to elevate the project by utilizing its advanced pressure forming capabilities, 6-axis robotic trimming and 3D inspection technology.

To find the right material, Ray Products collaborated with Sekisui Kydex’s appLab and designLab Innovation Centers, and engaged their R&D teams. Together, they developed Kydex 1100UV — a weatherable, proprietary alloy sheet that offers excellent formability, durability, break resistance and fire retardancy. By employing color measurement software throughout production, Ray Products maintained exceptional color consistency in each part, achieving quality control that would have been more difficult to achieve with painted components. Sheet was provided in thickness from 0.56 inch to 0.200 inch starting gauge.

Custom former Ray Products and sheet extruder Sekisui Kydex combined their expertise on materials development and processing technologies to create a thermoformed EV charging station. Source: Ray Products, Sekisui Kydex

Ray Products then developed the pressure-formed DC block housing unit, addressing the client’s need for a durable, weather-resistant enclosure that meets stringent aesthetic and functional requirements. The final 11-part enclosure was engineered for easy assembly with minimal attachment points, streamlining installation and eliminating the need for secondary processes. This design approach not only enhanced assembly efficiency but also contributed to the long-term structural integrity and reduced maintenance costs for the client.

Leveraging the advanced capabilities of pressure forming, Ray Products produced several thousand units with consistent quality, Ray says using Kydex 1100UV enabled greater design freedom, enabling it to deliver parts with integrated features and an exceptional finish that aligns with the brand and performance standards. The EV units have been deployed for more than a year.

“Too often pressure forming flies under the radar compared to other manufacturing processes, but our collaboration with Kydex shows the true value and impact it can make,” says Jason Middleton, Ray’s vice president of sales and development. “When others fell short, Ray stepped up.”

Ray Products’ production process included thorough in-line inspections and quality checks, ensuring every unit met the necessary UL certifications for safety and durability. Packaged and shipped directly to installation sites, the DC block enclosures arrive ready for immediate deployment without the need for inspection or repackaging by the OEM — a process improvement that redefines “dock-to-stock” efficiency, saving time and reducing handling costs.

Notes Ben Smalley, director of ����ý development for Sekisui Kydex, “It's because of partnerships with solution-oriented organizations like Ray Products that enable new innovative material development to happen."

Ray Product’s Middleton says success of the DC block project underscores the customer former’s ability to adapt and grow alongside emerging markets. With its expertise in high-precision thermoforming, he says Ray Products is well-positioned to support future advancements in charging station technology, providing faster, more flexible manufacturing options that reduce time-to-market and open new possibilities for product customization.